Panel assembly



y '19, 1 L. c. SCHAUB Em 2,887,192

PANEL 'ASSEMBLY 5 Sheets-Sheet '1 Filed July 13, 1950 INVENTORS L154: C. Jcxmua. Jar/N F. Buwru. BY w ATTORNEY May 19, 1959 L. c. SCHAUB ETAL 2,887,192

PANEL ASSEMBLY Filed July 13, 1950 5 Sheets-Sheet 2 Q [J s IN V ENTOR6 TTOR N E Y 1/54: 0. Jcrmua. JOHN EBA/9570.

May 19, 1959' L. c. SCHAUB r-rr u.

PANEL ASSEMBLY Filed July 13,1950

3 Sheets-Sheet 3 LI!!! IlIlIl-iiiij INVENTORJ Z/JLE C. 601 905. Jomv F. Bum/w.

' ATTORNIEY rangemeni at the construction site. i i

United States Patent PANEL ASSEMBLY Application July 13, 1950, Serial No. 113,632

6 Claims. 01. 1s9--34 This invention relates to sheet metal building construction. More particularly it is concerned with providing a metal panel assembly or arrangement for the roofs, walls, floors, etc., of buildings or the likewhich is comprised of a plurality of sheet metal units and which is capable of functioning as a floor, wall or roof, etc., 'in and of itself or alternately as a strong and rigid foundation for the same. M V

Although many metal panel arrangements have been devised in the past forthese purposes they have 'not proven entirely satisfactory particularly because of the cost factor involved in the manufacture ofthe same. i e i A These panel arrangements wereusually oi a; very complex and intricate design and in addition to the special equipment which had to be designed to manufacture the various parts and fittings special skill was also required in finally assembling these parts to form the panel arin addition, it was usually imperative that the various elements, such as fittings, structural members,fasteners, etc., which make up these panel assembliesfbej made of heavy gauge metal injorder for the panel assemblies to have the strength and rigidity requiredbythe local building codes. In some instances, particularly whenthe various parts were made from heavy gauge metals, the use of such panel assemblies has also been undesirableand impractical because of theyexcessive loads, and thus the advantages of construction have been ofiset. i i Attempts have also been made in the pas o utilize thin gauge metals in such panel assemblies, audio make the various parts of the panels from aluminum and other light metals. These havenot met with success, chiefly because of thefact that these metals coul dno meetgthe .strength requirements of the building code H so,'the various arrangements of fittings and supportingniembers Yweremore numerous and complicated yvithitheresultant excessive costs. I Accordingly, it is an object of thislirivention to provide a novel panel assembly of relativelysimple design and which has such inherent strength and rigidity that, its elements can be made from thingauge metals,aiid particularly light metals such as aluminum. A further object of this invention is to provide anovel panel assembly which may function eitherr as the roof, ,wallpartition or floor, etc., of a building, and the like in and of itself or alternately as a strong foundationfor the same. 1 v we 1 A further object of the invention is to providefafnovel panel. assembly of exceptionally simple design and one which can be manufactured and produced with aminjimum amount of expense. j Another object of this invention is to providefa j novel paneljassembly which can be erected at the building site ;with exceptional ease and without any extraord A further object of this invention is to p vi panel assembly, which will adequately ser'v as f yrs m. s

tion for a roof, floor, wall or the like and wherein the varand installation 2,887,192 P n ed M 9. .1 59

2 a ious load bearing members willbe of ample strength to withstand the loads imposed thereupon while employing lightweight metal sheets therewith. Another object of this invention is to provide a simple but eflicient means for connecting or joining the various elements of the panel assemblies together, as well as for joining one panel assembly to another. p

A further object of this invention is to provide a novel panel assembly wherein the various elements are so arranged that each elementserves to strengthen and reinforce theother elements thatare attached thereto.

Another object of this invention is to provide a novel panel assembly which isadapted to be easily and quickly dismantled. i These and other objects are accomplished by providing a panel assembly comprised of a plurality of box beams arranged in parallel, spaced relationship to each other. Each of the box beams is adapted to be supported by load bearingmembers or purlins arranged at right angles there to. Each of the box beams has walls which are succes; sivelybent so as to provide a contacting face of substantial area, having an open mouth or slot therein. Fastening clips are provided .for positively securing the box means to the load bearing members. i A plurality of corrugated sheets are arranged in parallel rows upon the box beams in such a manner that the corrugations of the sheets are locatedat right angles to the box beams and the ends and edges of the sheets overlap one another. Means are. also provided for positively fastening the cor: rugated sheets to the box beams, which means include a fastening member attachable to each sheet and having an enlarged tapered end portion. which is adapted to be pressed with a minimum amount of pressure into the open mouth on the contacting face of the beam so as to be.- come interlocked with each of the walls that form the mouth in the box beam.

Other objects and advantages of the present invention will be more apparent upon consideration of the follow.- ing detailed description, when taken in conjunction with the drawings wherein: i

Figure 1 is a perspective view ofa partially completed panel assembly; 1 i I Figure 2 is a top plan view of thepanel assembly show.- ing the staggered arrangement of the corrugated sheets in one row with respect to the sheets in adjacent rows; Figure 3 is a sectional view partially broken away corresponding to line 3 -3 in Figure 2 and disclosing the use of the panel assembly as a light weight metal foundation for a roof or the like and wherein a layer of insulating ma, terial has been applied to the eorrug a tedsheets;

Figure 4. isan elevational cross sectional view ofthe box beams or hollow rib elements of the assembly, where a suitable type of fastener is shown for attaching. the corrugated sheets to the hollow ribs;

Figure 5 is a broken diagrammatic view of twocoi'ru gated sheets and discloses the manner in which the sheets overlap each other. along their lengths when they are arranged side by side on the box beams; f

Figure 6 is a detailed view partially in section showing a preferred arrangement for fastening the box beams to a purlin or the like h Figure 7 is a cross sectional view taken along line 7 1 inFigure 6; e a a e a Figure 8 is a broken diagrammatic view of a corrugated sheet together with a modified type fastening strip. for

lockingthe, sheet to a beam;

Figure 9 is a detailed view partly in section showing tlie manner in which the fastening strip of Figure 8 is used for attaching the corrugated sheets to the box beams, a; gether with the arrangement for overlapping the ends oi the corrugated sheetsllojcatedin. thelsamerow, an "i Figure" IOis an 'elevational sectional view of a parapet assrnsa wall assembly, showing the manner in which the panel ass lelrnbly of the present invention may be attached to the wa Although the panel assembly of the present invention is well adapted for many uses and to varying conditions of installation, it will be particularly described with reference to its use in building structures, it being understood, however, that its use is not limited thereto and ,that it is also adaptable for use in constructing the walls, roofs, decks and floors of trailers, trucks, railroad cars, and ships.

As will be observed from the drawings, the panel assembly of the present invention is adapted to be employed, in conjunction with any conventional load hearing members such as purlins lthwhich usually are in the. form of I-beams. Extending across load bearing members 10 and at right angles thereto are a plurality of, supporting members 11. These supporting members 11 are arranged in spaced, parallel relationship to each other upon load bearing members 10 and are preferably rectangular or box-shaped in cross section.

In an advantageous embodiment of the invention each box beam or supporting member 11 is formed in such a way from a, sheet of metal of suitable strength and gauge, that it is provided with a fiat end or bottom 12, and side walls 13 the latter of which are successively bent at their upper extremities so as to form an upper supporting surface 14, provided with an open mouth or slot 15 definedv or encompassed by the downturned flanges or lips 16 on the supporting surface 14.

I .As shown in Figure 7 of the drawings, the downturned flan es 16, which define the open mouth portion 15, are so angled that they normally contact each other. They may be easily displaced, however, and sprung apart by a fastening member or the like, when it is inserted in the open mouth portion 15 and, passes therethrough into the hollow interior of the rib 11.

It will also be noted that the upper surface 14 of the box beams is of a sufficient area to provide a relatively large and satisfactory supporting surface for the sheets 17, which are preferably corrugated, and which are placed thereon and locked thereto in a manner that it to be hereinafter described.

As shown irfFigure l of the drawings the box means 11v may be secured to the load supporting members 10 by any suitable means such as by means of brackets 18, which are welded at one end to the box beams 11 and at their other end to the load supporting members 10. In the preferred embodiment of the invention, however, box beams 11 are secured to the load bearing member 10 through the medium of a plurality of clip fasteners 19 best shown in Figures 6 and 7 of the drawings.

Each of the clip fasteners 19 is generally comprised of a flattened bottom portion 20, which is welded to the upper flange 21 of purlin 10 and a hook-shaped upper portion 22 which is adapted to be inserted in an aperture 23 located in a side wall 13 of the box beam.

As shown in Figure l of the drawings, a plurality of pins 24 may also be welded, if desired, to the upper flanges 21 of the purlins to provide additional means for anchoring the box beams. The use of pins 24 has been found to be most advantageous, when the panel assembly is applied to a sloping roof surface or the like.

Referring now to Figures 2 and of the drawings. It will be seen thateach of the sheets 17 is generally comprised of a plurality of successive corrugations 25 made up of troughs 26 and crests 27.

These sheets are arranged upon the box beams so that their corrugations are at right angles thereto, i.e., the corrugations 25 run. parallel to the purlins 10. The

preferred arrangement also contemplates that the sheets 17 beplacedin parallel rows upon the box beams in such a manner that the ends of the sheets in one row are not in line with the ends. of the sheets in an adjacent row.

This staggered arrangement of the parallel rows of sheets provides for greater rigidity and strength of the panel assembly as a whole.

Referring to Figure 9 as well as Figure 2 it will be observed that the sheets in each parallel row are so arranged that the end of one sheet is overlapped by an adjacent sheet in the same row. As shown in Figure 5, provision is also made for overlapping the side longitudinal edges of the sheets in one row with the longitudinal edges or sides of the sheets in an adjacent parallel row.

This overlapping of the corrugated sheets at the end and sides provides a continuous contact between all the sheets at all times and restricts any leakage of water, etc., therethrough.

In the event that the panel assembly is used as a foundation or decking for a roof and the like certain of the load bearing members 10 are fastened directly to the side walls 30 of a building and the box means and sheet 17 are partially supported thereon (see Fig. 10). A suitable insulating material 31 such as asbestos or felt is adhesively united, to the upper surfaces of the sheets 17 after which a strip of metal 32 which has the properties of a vapor seal is placed upon the insulating material and the cant strip 33 located adjacent the wall 30 and above the panel foundation assembly. A coating of asphalt may be used to protect the insulation in lieu of strip 32 or as a substitute for the insulation itself.

When the panel is used as such a foundation the overlapping arrangement of the sides and ends of the sheet is of considerable help in reducing to a minimum the leakage of hot asphalt or the like through the sheets while at the same time rendering the surface waterproof.

Means are also provided for efliciently locking the sheets 17 to the box beams 11. Referring to Figure 4 one advantageous embodiment of the invention contemplates the use of nail-like fasteners or clips 35. Each of these fasteners is comprised of a head portion 36, a Shank 37 and an enlarged tapered end or point 38.

A-series of these fastening clips 35 are first driven through suitable holes provided in the several troughs 26 in the corrugations of each sheet 17 directly above and in alignment with the slots 15 located in the upper surfaces of the box beams, which support the sheet 17. The fasteners are then forced through the slot 15 of the box beams until the enlarged point 38 of each fastener clears the slot 15 and the downwardly turned flanges or lips 16 on the box beam close about the shanks 37 of these fastening clips thereby locking sheet 17 to box beam 11. The enlarged, tapered shape of the point 38 permits easy insertion of the fastener into the box beam and with the use of relatively little pressure, since the tapered shape of point 38 causes it to act in the manner of a cam which forces the flanges 16 apart and allows them to come together to close about the thin shank 37 of the fastener, once the point 38 has passed intothe hollow interior of the rib 11.

Although the enlarged point 38 successfully prevents removal of the sheet upwardly because of the abutting relationship between the shoulders 43 of the point 38 and flanges, 16 of the sheets, it will be observed that the sheets may be easily moved sideways for the purposes of adjustment or removal from the box beam.

A modified form of fastening means for securing the sheets'17to the box beams 11 is disclosed in Figures 8 and 9, and is generally comprised of an elongated snapon fitting or strip 40. This snap-on fitting is generally V shaped in cross section and one of its legs 41 is bent back at an angle to form a projecting tongue 42.

These strips are welded or otherwise suitably fastened to the underside of the corrugated sheets 17, and preferably run in a direction which is at right angles to the corrugations of the sheet and parallel with the slots 15 of the box beams.

When the leg portion 41 of this fastener, together, with itsprojecting tongue 42, is forced through the slot and into the hollowed out interior of the box beam, the sheets 17 are securely locked to the box beams, and upward removal of the sheets from the box beam is prevented because of the locking action that takes place between the projecting tongue 42 of the strip and the downturned flanges 16 of the box beam.

As in the case of the clip fasteners 35 the tapered shape of the lower part of the strip 40 permits easy insertion of the strip within the box beam because of the cam-like action of leg 41 and tongue 49,, when they are forced into the mouth 15 of the box beam.

Again, as in the case of the clip fastener shown in Figure 4, any great uplift of the sheets is effectively prevented, which is essential to prevent ripping off of the roof byjhigh winds. j

When snap-on fasteners or strips 40 are used, however, movement of the sheets sideways, is still permitted in the event sidewise adjustment or removal of the sheets is desired.

It will also be observed by referring to Figure 8 of the drawings that this strip 40 does not extend along the entire width of the sheet, and is not integral with nor fastened immediately to the ends of the sheets. This provides for efficient fastening of the sheets to the box beams without raising any problems as to the proper overlapping of the sides and edges of the sheet while still effectively joining the sheets to the box beams and to each other. In addition this arrangement also aifords the additional advantage of providing the maximum amount of bearing surface for each individual sheet.

When riveted or screw connections 50 are used between the snap-on fittings 40 and the sheets 17 provision can also be made for lengthwise adjustment of the sheets, as well as sidewise adjustment, by providing a suitable series of holes lengthwise of the sheet 17 for these rivets or screws, such a series of holes 50' being shown in the troughs of the corrugated sheet disclosed in Fig. 4 of the drawings.

The number of these snap-on fittings as well as the number of rows of fastening clips 35 to be used with sheet 17 will depend upon the number of box beams used to support each individual sheet as well as the results desired.

This panel assembly arrangement permitting the use of corrugated sheets wherein the corrugations run lengthwise of the sheet and at right angles to the box beams provides an arrangement wherein the strength and stiffness afforded by the corrugations can be used to the utmost.

This type of construction also takes full advantage of beam action due primarily to the fact that the corrugations run at right angles to the box beam. The advantage of continuous beam action is also present in that a series of box beams are crossed with the sheets.

Each sheet as it is fastened in place also automatically assists in locking the adjacent sheet in the same or other rows to the box beams because of the overlapping arrangement of the sides and ends of the sheet.

Thus it will be seen that a novel type of panel assembly has been provided which because of its design has such inherent strength and rigidity that thin gauge metals may be used.

The box beam 11 is advantageously made of spring steel and the corrugated panel is made of aluminum. However, these components may be made of any suitable metal such as steel, aluminum, or magnesium, or the like, and still provide the outstanding advantages of low cost, high strength, light weight as a consequence of utilization of thin gauge metals, and ease of erection and dismantling.

'An advantageous arrangement of the invention has been herein illustrated and described. It will be understood, however, that changes in the construction and design of the parts may be made without departing either from the true spirit or scope of the inventionas defined by theappended claims.

What is claimed is:

l. A panel assembly of the type described, comprising the combination of a plurality of load bearing members, a plurality of hollow ribs mounted upon said load bearing members and at right angles thereto, each of said hollow ribs having resilient upstanding side walls and a top contacting face having an elongated open mouth therein, a corrugated sheet supported by and fastened to said hollow ribs in sucha manner that the corrugations thereof are arranged injparallel relationship with said load bear- ,ing members, and fastening means securing said corrugated sheet to said hollow ribs, said means including a plurality of elongated locking strips fastened to the underside of saidcorrugated sheet intermediate its side edges and at a transverse angle to said corrugations, each of said locking strips having at the lower portion thereof a projecting tongue portionwhich is pressed into inter, locking engagement with theopen mouth on one of the said hollow ribs. j =2. In a construction of, the character described, a plurality of box beams supported by a plurality of load bearing members arranged at right angles thereto, each of said hollow ribs having resilient upstanding side walls and a top contacting face, said contacting face being provided with an elongated open mouth defined by resilient downwardly projecting abutting walls, a plurality of corrugated sheet panels mounted in parallel rows upon and fastened to said box beams in such a manner that the corrugations thereof. are located at right angles to said box beams and the ends of the panels in one row are out of alignment with the ends of panels in an adjacent row, fastening means securing said corrugated sheets to said box beams, said means including a plurality of locking strips adjustably fastened to the underside of said corrugated sheets intermediate the marginal edges thereof and at an angle to said corrugations, each of said locking strips at the lower portions thereof having a projecting tongue portion which is pressed into the open mouth of a box beam and into interlocking engagement with each of the walls on the said box beam that form the open mouth thereon.

3. In a unit panel assembly of the type described, the combination of a load bearing member, a hollow rib mounted upon said load bearing member at right angles thereto, said hollow rib having resilient upstanding side walls and a top contacting face provided with an elongated open mouth defined by resilient downwardly projecting abutting walls, securing means fastening said rib to said load bearing member, a corrugated sheet supported by and fastened to said hollow rib in such a manner that the corrugations thereof are arranged in parallel relationship with said load bearing member, and securing means fastening said corrugated sheet to said hollow rib, said means including an elongated rigid locking strip adjustably fastened to the underside of said corrugated sheet and at right angles to said corrugations, said strip having a projecting tongue portion which is pressed into the open mouth of said hollow rib and into interlocking engagement with each of the walls on said hollow rib that form the open mouth thereon.

4. In a unit panel assembly of the type described, the combination of a plurality of load bearing members and a plurality of box beams, each of said box beams having resilient upstanding side walls and a top contacting face provided with an elongated open mouth defined by resilient downwardly projecting walls, said box beams being supported by and arranged upon said load bearing members at substantially right angles thereto, a corrugated sheet supported by and fastened to said box beams, and secured means fastening said corrugated sheet to said box beams, said means including a plurality of elongated rigid locking strips fastened to the undersurface of said corrugated sheet intermediate the marginal edges thereof and at an angle to said corrugations, said strips having projecting tongue portions at the lower parts thereof which are pressed into the open mouths of said box beams and interlockingly engage the walls of said box beams which define the said mouths in each of said beams.

5. In a load bearing panel assembly of the type described, the combination of a box beam arranged at an angle upon and supported by a load bearing member, said box beam having resilient upstanding side walls and a top contacting face of substantial area and said contacting face having an open mouth portion defined by resilient downwardly projecting abutting walls, one of the Walls on said box beam also being provided with an aperture in a side thereof, a clip fastener rigidly secured to said load bearing member and having a hooked end portion which is inserted in the aperture in said wall of said box beam, a corrugated sheet mounted upon said box beam in such a fashion that the corrugations thereof are located at an angle to said box beam, and means securing said sheet to said box beam, said means including an elongated rigid locking strip fastened to the undersurface of said corrugated sheet intermediate the side edges thereof and at an angle to said corrugations, said locking strip having a locking tongue which is pressed into interlocking engagement with the walls on said box beam that form the said open mouth portion.

6. The combination defined in claim 4, including means adjustably attaching said strips to the said sheet.

References Cited in the file of this patent UNITED STATES PATENTS 1,035,582 Halinka Aug. 13, 1912 1,620,130 Pietzsch Mar. 8, 1927 1,714,682 Loucks May 28, 1929 1,778,337 Pratt Oct. 14, 1930 1,949,543 'Loucks Mar. 6, 1934 1,997,939 Loucks Apr. 16, 1935 2,171,540 Calkins et a1 Sept. 5, 1939 2,278,822 Benz Apr. 7, 1942 2,447,694 Finch Aug. 24, 1948 2,457,250 Macomber Dec. 28, 1948 2,467,558 Kapnek Apr. 19, 1949 2,476,506 Olsen July 19, 1949 2,590,687 Crafton Mar. 25, 1952 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 2,887,192 May 19 1959 Lisle G. Schaub et al.

It is hereby certified that error appears in the -printed specification of the above-numbered patent requiring correction and that the said Letters Patent should read as corrected below.

Column 3, line 43, for "that it" read that is column 4, line 19, for "means" read beams line 45, for "slot" read slots column 6, line '72, for "secured" read securing Signed and sealed this 17th day of November 1959.

(SEAL) Attest:

KARL H. AXLINE ROBERT c. WATSON Attesting Officer Commissioner of Patents 

